Fresh food compartment ice box door

ABSTRACT

A refrigerator has a compartment defined by a liner. A door is configured to provide access into the compartment. A sub-compartment is mounted in the door. The sub-compartment has an access door that opens to provide access into the sub-compartment. The access door includes an inner door panel, an outer door panel, and a vacuum insulation panel disposed between the inner and outer door panels.

FIELD OF THE INVENTION

The present subject matter relates generally to refrigerators, and more particularly to a refrigerator with a freezer sub-compartment in the fresh food section.

BACKGROUND OF THE INVENTION

Generally, a refrigerator includes a freezer compartment and a fresh food compartment, which are partitioned from each other to store various foods at appropriate low temperatures.

It is a common practice to provide an automatic icemaker/water dispenser with a refrigerator. In a “side-by-side” type of refrigerator where the freezer compartment is arranged to the side of the fresh food compartment, the icemaker is usually disposed in the freezer compartment and, thus, utilizes the cold air in the freezer compartment, which typically includes an evaporator disposed in the freezer compartment.

In a “bottom freezer” type of refrigerator where the freezer compartment is arranged beneath a top mounted fresh food compartment, convenience necessitates that the icemaker is disposed in a thermally insulated sub-compartment (often referred to as an “icebox”) configured in one of the top mounted fresh food compartment doors, with ice delivered through an opening on the door. In such an arrangement, provision must be made for providing adequate cooling to the icebox to enable the icemaker to form and store the ice.

An access door is typically provided on the icebox to allow the consumer to access the internal ice bucket and icemaker. This door is typically insulated with foam between inner and outer door panels. Unfortunately, the access door is relatively thick and valuable space in the fresh food compartment is sacrificed to accommodate the insulated door.

The conventional design of the icebox access door is problematic from another standpoint. The temperature differential between the icebox and the fresh food compartment is substantial, often resulting in significant condensation (“sweating”) accumulating on the outer surface of the icebox door. This condensation is a highly visible and unsightly irritant to consumers when they open the fresh food compartment, and generates an impression of inferior appliance quality.

Accordingly, it would be desirable to provide an icebox door assembly that eliminates the sweating problem of conventional doors without increasing the depth of the door.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In an exemplary embodiment, a refrigerator is provided with a compartment defined by a liner, for example a fresh food compartment defined by a fresh food liner. A door is configured with the compartment to provide access into the compartment and to seal the compartment in the closed position of the door. A sub-compartment is mounted in the door. This sub-compartment may, in one particular embodiment, constitute a freezer sub-compartment with an icemaker and an ice storage bin. The sub-compartment has an access door that opens to provide access into the sub-compartment. The access door may be variously configured in accordance with aspects of the invention. In a particular embodiment, the access door includes an inner door panel, an outer door panel, and a vacuum insulation panel disposed between the inner and outer door panels. The type and thickness of the vacuum insulation panel is selected so as to provide desired thermal insulating characteristics to the access door, particularly a thin profile that also prevents or at least significantly reduces sweating on the outer door panel. In a particular embodiment, the access door has a total thickness of less than 0.5 inches, with the vacuum insulation panel having a thickness of about 0.2 inches.

In a further embodiment, the access door includes an additional insulation material disposed against the vacuum insulation panel between the door panels. The vacuum insulation panel and the additional insulation material may have a combined thickness of less than 1.0 inch, for example a combined thickness of about 0.5 inches. In this embodiment, the access door may have a total thickness of less than 0.75 inches.

The additional insulation material may be a spray foam that is injected between the inner and outer door panels, with the vacuum insulation panel disposed against the inner door panel and the foam injected between the vacuum insulation panel and the outer panel door and formed around a periphery of the vacuum insulation panel. In this embodiment, the access door may have a total thickness of less than 0.75 inches. In other embodiments, the vacuum insulation panel may be disposed against the outer door panel, with the foam injected between the inner door panel and the vacuum insulation panel. The vacuum insulation panel may be spaced from both of the inner and outer door panels with the foam essentially encasing the vacuum insulation panel in still other embodiments.

In another embodiment, the additional insulation material may be a pre-formed sheet material, with the vacuum insulation panel disposed against the inner door panel and the pre-formed sheet material disposed between the vacuum insulation panel and the outer panel door. The pre-formed sheet material may be, for example, a closed-cell polystyrene foam sheet, or a cast polyurethane sheet.

A gasket seal may be disposed around an opening to the sub-compartment, with the inner panel of the access door sealing against the gasket seal in a closed position of the access door. The vacuum insulation panel may have dimensions so as to extend outboard of a periphery of the gasket seal.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a perspective view of an exemplary refrigerator that may incorporate aspects of the invention;

FIG. 2 is a perspective view of a sub-compartment configured on a fresh food compartment door of a refrigerator;

FIG. 3 is a perspective view of the sub-compartment with the access door in an open position;

FIG. 4 is a component view of a particular embodiment of an access door;

FIG. 5 is a cross-sectional view of the access door of FIG. 4;

FIG. 6 is a cross-sectional view of another embodiment of an access door;

FIG. 7 is a component view of another embodiment of an access door; and

FIG. 8 is a cross-sectional view of the access door of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 depicts a refrigerator 10 in accordance with an exemplary embodiment of the invention. The refrigerator 10 has an outer casing 12 and inner liner 24 (FIG. 2) that define an upper fresh food compartment 14 with a frontal access opening through doors 16 and 18, and a lower freezer compartment 20 a frontal access opening through door 22. The type of refrigerator depicted in FIG. 1 is generally referred to as a French-style refrigerator wherein the fresh food compartment 12 is configured above the freezer compartment 20 and includes two French doors 16, 18. In an alternate embodiment, a single door can be used instead of the dual doors 16, 18.

It should be appreciated that the present invention is not limited to any particular type or style of refrigerator, and that the refrigerator 10 depicted in FIG. 1 is for illustrative purposes only.

An ice/water dispenser 26 is configured in the door 18 of the fresh food compartment 14. This dispenser 26 is serviced by a freezer sub-compartment 28 (FIGS. 2 and 3) mounted on the back side of the door 18. This compartment 28 is often referred to as an “icebox.” Referring to FIGS. 2 and 3, the sub-compartment 28 includes end walls 30 (top and bottom) and side walls 32 that extend into the fresh food compartment 14 in the closed position of the door 18. An icemaker 34 and ice storage bin 36 (partially visible in FIG. 3) are typically housed within the sub-compartment 28.

An opening 38 is defined in one of the side walls 32 of the sub-compartment 28 and is configured for mating to a cold air supply in the fresh food compartment liner 24 in a closed position of the door 18. Any manner of suitable gasket is provided around the opening 38 to compress and seal against the liner wall when the door 18 is closed. In order to provide a source of cold air to the sub-compartment 28, a cold plate assembly (not visible in the figures) is disposed within (behind) the liner 24 with an outlet in the compartment side wall that mates with the opening 38 in the closed position of the door 18. A fan may be provided in the sub-compartment 28 to draw the cold air into the compartment.

Referring to FIG. 3, sub-compartment 28 has a front opening 42 defined by a front rim wall 43. Any manner of suitable gasket material 62 is provided around the opening 42 on the front rim wall 43. An access door 40 is hinged to the front rim wall 43 by any manner of suitable hinge mechanism 44. The access door 40 seals against the gasket material 62 in a closed position of the access door 40. It should be appreciated that the gasket material 62 may be provided on the door 40 to seal around the front rim wall 43 in the closed position of the door 40. Any manner of suitable latch 64 is configured with the sub-compartment 28 to maintain the access door 40 in the closed position. The latch 64 may be actuated by the consumer in order to open the access door 40 for providing access into the internal space of the sub-compartment 28.

The access door 40 may be variously constructed. In the embodiment of FIGS. 4 and 5, the access door 40 includes an inner door panel 46, an outer door panel 48, and a vacuum insulation panel 50 disposed between the door panels 46, 48, for example against the inner door panel 46, against the outer door panel 48, or intermediate and spaded from both of the door panels 46, 48. The door panels 46, 48, may be formed of any suitable material, including metal, molded plastic components, and the like. In the illustrated embodiment, the panels 46, 48 are defined by separate components that are eventually configured together to form the door 40. It should be appreciated, however, that other constructions are also possible. For example, the panels 46, 48 may be formed together as a unitary component with a space between the members, such as in a pouch or envelope construction, with the panels 46, 48 defining the inner and outer sides or walls of the door 40.

In the particular non-limiting embodiment illustrated in FIGS. 4 and 5, the outer door panel 48 includes a circumferential lip 49 that extends over the inner door panel 46, as particularly illustrated in FIG. 5. The door panels 46, 48 may be attached together by any suitable means, including adhesives, mechanical fasteners, and the like.

Referring to FIG. 5 in particular, it may be desirable in certain embodiments for the inner door panel 46 to include a raised bed 58 defined by a shoulder 60. The vacuum insulation panel 50 may be disposed against the raised bed 58, as particularly illustrated in FIG. 5, and sandwiched between the raised bed 58 and the inner surface of the outer door panel 48.

The construction and function of vacuum insulation panels is well known by those skilled in the art and need not be described in detail herein. Vacuum insulation panels are readily obtainable from any number of commercial sources and can be provided with precise dimensions as needed. The type and thickness of the vacuum insulation panel 50 is selected so as to provide desired thermal insulation characteristics to the access door 40. Desirably, the thickness of the vacuum insulation panel is selected so as to provide the access door 40 with a relatively thin profile yet prevent or at least significantly reduce sweating on the outer door panel 48. In a particular embodiment, the access door 40 has a total thickness of less than 0.5 inches, with the vacuum insulation panel 50 having a thickness of about 0.2 inches.

In additional embodiments of the access door 40, an additional insulation material 52 may also be provided between the inner door panel 46 and the outer door panel 48. For example, referring to FIG. 6, the additional insulation material 52 may comprise a spray polyurethane foam (SPF). Use of SPF's for insulation purposes in consumer appliances is a common practice. After the access door 40 is assembled with the vacuum insulation panel 50 between the door panels 46, 48, for example adhered against the inner door panel 46, the SPF may be injected into the remaining space between the panels 46, 48 via any manner of port or injection hole 55 (FIG. 4). The spray foam migrates throughout the interior volume of the door 40 and forms around the periphery of the vacuum insulation panel 50, as well as in the planar space defined by the opposing surfaces of the vacuum insulation panel 50 in the inner surface of the outer door panel 48, as particularly illustrated in FIG. 6.

It should be appreciated that the use of an SPF may serve additional benefits. The foam, when cured, serves to further bond the components of the access door 40 together, and adds significant structural rigidity to the access door 40.

In the embodiment illustrated in FIGS. 7 and 8, the additional insulation material 52 may be a pre-formed sheet of insulation material having defined dimensions, thickness, and insulation properties. For example, the sheet 56 of additional insulation material may be a cast polyurethane sheet, a closed-cell expanded polystyrene foam sheet, and the like.

In the embodiments wherein the access door 40 includes the additional insulation material 52, the vacuum insulation panel 50 and the additional insulation material 52 may have a combined thickness of less than 1.0 inch, for example a combined thickness of about 0.5 inches. In a particular embodiment, the access door 40 has a total thickness (including the vacuum insulation panel 50 and the additional insulation material 52) of less than 0.5 inches.

As can be readily seen in FIGS. 5, 6, and 8, the gasket seal 62 is disposed around the opening 42 in the sub-compartment 28 and the inner panel 46 of the access door 40 seals against the gasket 62 in a closed position of the door 40. In this particular embodiment, the vacuum insulation panel 50 that is disposed against the inner surface of the door panel 46 has dimensions so as to circumferentially extend outboard of the periphery of the gasket seal 62, as particularly seen in FIGS. 5, 6, and 8.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

1. A refrigerator, comprising: a compartment defined by a liner; a door configured to provide access into said compartment; a sub-compartment mounted in said door, said sub-compartment having an access door that opens to provide access into said sub-compartment, said access door further comprising: an inner door panel; an outer door panel; and a vacuum insulation panel disposed between said inner door panel and said outer door panel.
 2. The refrigerator as in claim 1, wherein said compartment is a fresh food compartment and said sub-compartment comprises a freezer sub-compartment with an icemaker and ice cube storage bin.
 3. The refrigerator as in claim 1, wherein said access door has a total thickness of less than 0.5 inches.
 4. The refrigerator as in claim 1, further comprising an additional insulation material disposed against said vacuum insulation panel.
 5. The refrigerator as in claim 4, wherein said vacuum insulation panel and said additional insulation material have a combined thickness of less than 1.0 inch.
 6. The refrigerator as in claim 5, wherein said vacuum insulation panel and said additional insulation material have a combined thickness of about 0.5 inches.
 7. The refrigerator as in claim 6, wherein said access door has a total thickness of less than 0.75 inches.
 8. The refrigerator as in claim 4, wherein said additional insulation material comprises a spray foam that is injected between said inner and outer door panels, said vacuum insulation panel disposed against said inner door panel, said foam injected between said vacuum insulation panel and said outer panel door and formed around a periphery of said vacuum insulation panel.
 9. The refrigerator as in claim 8, wherein said access door has a total thickness of less than 0.75 inches.
 10. The refrigerator as in claim 8, wherein said inner door panel comprises a raised bed on which said vacuum insulation panel is attached, said foamed formed around the periphery of said vacuum insulation panel and said raised bed.
 11. The refrigerator as in claim 4, wherein said additional insulation material comprises a pre-formed sheet material, said vacuum insulation panel disposed against said inner door panel and said pre-formed sheet material disposed between said vacuum insulation panel and said outer panel door.
 12. The refrigerator as in claim 11, wherein said access door has a total thickness of less than 0.75 inches.
 13. The refrigerator as in claim 12, wherein said pre-formed sheet material comprises a closed-cell polystyrene foam sheet.
 14. The refrigerator as in claim 12, wherein said pre-formed sheet material comprises a cast polyurethane sheet.
 15. The refrigerator as in claim 1, further comprising a gasket seal disposed around an opening to said sub-compartment, said vacuum insulation panel having dimensions so as to extend outboard of a periphery of said gasket seal. 